JP3785105B2 - Dissimilar metal member joining method - Google Patents
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Description
【０００１】
【技術分野】
本発明は，摩擦撹拌接合法を用いて異種金属を接合する方法及び異種金属接合部材に関する。
【０００２】
【従来技術】
例えば，鉄鋼材料とアルミニウム合金材料という異種金属部材を接合して使用したい場合がある。この場合に，従来の融接によって両者を接合した場合には，接合界面に脆い金属間化合物（Ｆｅ2Ａｌ5等）が生成するので接合強度が低いという問題がある。このような問題は，アルミニウム合金とマグネシウム合金との接合，その他の異種金属部材の接合においても同様である。そのため，融接以外の異種金属部材の接合方法として，爆着，接着，回転摩擦圧接，リベット又はボルトによる接合，かしめなどが採用されてきた。
【０００３】
【解決しようとする課題】
しかしながら，上記従来の異種金属部材の接合方法においては，次の問題がある。
即ち，上記爆着は，大がかりな設備が必要であり，さらに爆音が問題とならない環境が必要となる。また，上記接着は，その養生に長時間かかり，かつ，長期信頼性が低い。上記回転摩擦圧接も信頼性に問題がある。リベット又はボルトによる機械的接合は，これらボルト等の第３部材が必要であるうえ，緩み発生のおそれがある。また，かしめによる接合も，接合強度が低く，緩み発生のおそれがある。
【０００４】
このような背景のもと，異種金属部材を従来よりも容易かつ確実に接合することができる方法の開発が求められていた。
本発明はかかる従来の問題点に鑑みてなされたもので，異種金属部材を容易かつ確実に接合することができる接合方法及びその接合方法により接合してなる異種金属接合部材を提供しようとするものである。
【０００５】
【課題の解決手段】
第１の発明は，融点の異なる異種金属よりなる２種類の金属部材を接合する方法であって，
融点の高い方の第１金属部材と，融点の低い方の第２金属部材とを重ね合せ，
肩面と該肩面から突出させた突起部とを先端に有すると共に上記第２金属部材よりも硬質の回転工具を用い，
該回転工具を回転させながら上記突起部を上記第２金属部材の表面から差し込み，上記突起部の先端と上記第１金属部材との間に間隔を保持すると共に，上記第２金属部材の金属を摩擦熱を発生させた状態で撹拌し，その撹拌域を上記第１金属部材に達する範囲に形成することにより，上記第１金属部材と上記第２金属部材とを接合するに当たり，
上記突起部を上記第２金属部材に差し込んだ際には，上記肩面をも該第２金属部材内部に差し込み，かつ上記肩面の差し込み量は，上記第２金属部材における上記肩面を差し込む部位の厚みの３０％以下であり，
上記突起部の先端と上記第１金属部材との間の間隔は０．０５ｍｍ以上０．５ｍｍ未満であることを特徴とする異種金属部材の接合方法にある（請求項１）。
【０００６】
本発明の接合方法においては，いわゆる摩擦撹拌接合方法に用いられる回転工具と同様の上記回転工具を用いて，上記第１金属部材と第２金属部材を重ね合わせて接合を行う。このとき，上記回転工具は，上記のごとく，その突起部を融点の低い方の第２金属部材に差し込み，これが第１金属部材には直接接触しないように，間隔を保持して位置させる。
【０００７】
そして，上記回転工具によって，上記第２金属部材の金属を摩擦熱を発生させた状態で攪拌し，その攪拌域を上記第１金属部材の表面，すなわち第１金属部材と第２金属部材との接合界面にまで到達させる。これにより，撹拌された第２金属部材の金属が第１金属部材に強固に接合される。
【０００８】
そして，この第１金属部材と第２金属部材の接合部は，溶融することなく形成されるので，融接を行った場合のように脆い金属間化合物が生成して接合強度が低くなるといったような問題が生じない。さらに，従来の他の接合法における問題点も解消することができ，異種金属である第１金属部材と第２金属部材とを容易かつ確実に接合することができる。
【０００９】
また，本発明においては，上記回転工具を上記第１金属部材に直接接触させることなく接合を行う。そのため，第１金属部材が非常に高硬度のものであっても，第１金属部材や回転工具にダメージを与えることなく接合を実現することができる。
【００１０】
このように本発明によれば，異種金属部材を容易かつ確実に接合することができる接合方法を提供することができる。
【００１１】
第２の発明は，融点の異なる異種金属よりなる２種類の金属部材を接合する方法であって，
融点の高い方の第１金属部材と，融点の低い方の第２金属部材とを重ね合せ，
肩面と該肩面から突出させた突起部とを先端に有すると共に上記第１金属部材よりも硬質の回転工具を用い，
該回転工具を回転させながら上記突起部を上記第２金属部材の表面から差し込み，上記突起部を上記第１金属部材に直接接触させてその表面粗さを粗くすると共に，上記第２金属部材の金属を摩擦熱を発生させた状態で撹拌し，その撹拌域を上記第１金属部材に達する範囲に形成し，かつ，上記回転工具を上記第１金属部材と上記第２金属部材との接合界面に平行に移動させることにより，上記第１金属部材と上記第２金属部材とを線接合するに当たり，
上記突起部を上記第２金属部材に差し込んだ際には，上記肩面をも該第２金属部材内部に差し込み，かつ上記肩面の差し込み量は，上記第２金属部材における上記肩面を差し込む部位の厚みの３０％以下であり，
上記突起部と上記第１金属部材との接触深さが１００μｍ以下であることを特徴とする異種金属部材の接合方法にある（請求項１０）。
【００１２】
本発明の接合方法においては，上記のごとく，上記回転工具として第１金属部材よりも硬質のものを用いる。そして，上記回転工具を回転させながら融点の低い方の第２金属部材に差し込み，上記第１金属部材に突起部を直接接触させる。これにより，上記突起部によって第１金属部材の表面を面粗しすることができる。
【００１３】
そして，上記回転工具を回転させながら接合界面に平行に移動させることによって，上記第２金属部材の金属を摩擦熱を発生させた状態で攪拌し，その攪拌域を上記第１金属部材における面粗しした面に到達させる。これにより，撹拌された第２金属部材の金属が第１金属部材に強固に接合され，回転工具の移動に沿った線状の接合部が形成される。
【００１４】
特に本発明では，上記回転工具によって第１金属部材の表面を面粗しして，この面を接合界面とすることができるので，より強固な接合効果を得ることができる。また第１金属部材の面粗しを予めやっておく必要もない。その他は，上記第１の発明と同様の作用効果を得ることができる。
このように上記第２の発明によっても，異種金属部材を容易かつ確実に接合することができる接合方法を提供することができる。
【００１５】
融点の異なる異種金属よりなる２種類の金属部材を接合してなる異種金属接合部材であって，上記第１の発明又は第２の発明の接合方法により接合してなることを特徴とする異種金属接合部材がある。
この異種金属接合部材は，上記の第１の発明又は第２の発明の優れた接合方法により接合してある。そのため，融接あるいはその他の接合方法により接合した異種金属接合部材に比べて，接合の信頼性が高く，また緩みの発生もない。そしてそのため，本発明の異種金属接合部材は，その適用範囲を従来よりも拡大することもできる。
【００１６】
【発明の実施の形態】
まず上記第１の発明（請求項１）の好ましい実施の形態につき説明する。
上記突起部を上記第２金属部材に差し込んだ際の上記突起部の先端と上記第１金属部材との間隔は，上記第２金属部材における上記突起部を差し込む部位の厚みの５０％以下であることが好ましい（請求項２）。
【００１７】
上記間隔が５０％を超えると，上記回転工具の回転により形成される撹拌域が第１金属部材に達しない，あるいは達しても接触面積が小さくなり，十分な接合が得られないおそれがある。そのため，より好ましくは上記間隔を上記第２金属部材における上記突起部を差し込む部位の厚みの３０％以下とするのがよい。
また，特に上記間隔の絶対値としては０．５ｍｍ未満とすることが好ましい。０．５ｍｍを超えると，上述したような撹拌域が第１金属部材に接する面積が小さくなって接合強度が弱くなるという不具合が生じやすくなる。なお，安定した接合作業を実現するためには，上記間隔を０．０５ｍｍ以上に設定することが好ましい。
【００１８】
上記回転工具の上記突起部は，その突出量が上記第２金属部材における上記突起部を差し込む部位の厚みより小さいことが好ましい（請求項３）。この場合には，上記回転工具を第２金属部材に差し込んだ際に上記突起部が第１金属部材に接触することをより確実に回避することができる。
【００１９】
また，上記突起部を上記第２金属部材に差し込んだ際には，上記肩面をも該第２金属部材内部に差し込み，かつ上記肩面の差し込み量は，上記第２金属部材における上記肩面を差し込む部位の厚みの３０％以下とする。この場合には，上記肩面を差し込んでの回転によって上記撹拌域を広くすることができ，接合部の強度を高めることができる。一方，上記肩面の差し込み量がその差し込み部位の厚みの３０％を超える場合には，接合部分の厚みが薄くなり，接合強度向上効果が低下してくるという問題がある。それ故，より好ましくは，上記肩面の差し込み量をその差し込み部位の厚みの１０％以下とすることがよい。
【００２０】
上記突起部を上記第２金属部材に差し込んだ後，その差し込み方向と逆方向に引き抜くことにより点接合を行うことが好ましい（請求項４）。この場合には，上記回転工具を回転させながら第２金属部材に差し込み，これをそのまま後退させて引き抜くことにより，容易に接合を実現することができる。そのため，接合装置の構造，接合作業等を簡単にすることができる。
【００２１】
また，上記突起部を上記第２金属部材に差し込んだ状態で，上記回転工具を上記第１金属部材と上記第２金属部材との接合界面に平行に移動させることにより線接合を行うこともできる（請求項５）。この場合には，線状の接合部分を形成することができ，より強固な接合を実現することができる。
【００２２】
また，上記第２金属部材の端面が上記第１金属部材の表面上に位置するように該第２金属部材を配置し，上記回転工具の上記突起部を，上記第２金属部材の端面又はその近傍から，上記第１金属部材と上記第２金属部材との接合界面に対する垂直方向から所定角度傾斜させた状態で差し込むこともできる（請求項６）。この場合には，いわゆる隅肉接合を実現することができる。
【００２３】
また，上記第１金属部材は鋼部材であり，上記第２金属部材はアルミニウム合金部材であることが好ましい（請求項７）。この場合には，上記接合方法の作用効果を特に有効に発現させることができ，従来困難であった鋼部材とアルミニウム合金部材との接合を容易かつ強固に行うことができる。
【００２４】
また，少なくとも上記第２金属部材との接合界面における上記第１金属部材の表面粗さはＲｚで１〜２０μｍの範囲内にあることが好ましい（請求項８）。ここでいうＲｚは，ＪＩＳ Ｂ０６０１−１９８２に示されている十点平均粗さであって，その測定方法も上記ＪＩＳ規格に規定された方法を用いる。
【００２５】
また，上記表面粗さを調整する方法としては，ペーパーややすり等の研磨具による研磨，エッチング，レーザ等の高密度エネルギービームの照射による面粗し，凹凸のあるロールを用いた圧延等，様々な方法を用いることができる。なお，この表面粗さの調整は，少なくとも接合界面となる表面に行えばよい。
【００２６】
上記第１金属部材の表面粗さがＲｚで１μｍ未満の場合には，上記接合方法による接合力が十分に得られない場合があり，それ故，より好ましくは２μｍ以上がよい。一方，上記Ｒｚが２０μｍを超える場合には，接合界面に空気層（隙間）が残り接合強度が低下するという問題があり，それ故，より好ましくは１０μｍ以下がよい。
【００２７】
また，少なくとも上記第２金属部材との接合界面における上記第１金属部材の表面粗さはＲｍａｘで５〜１００μｍの範囲内にあることが好ましい（請求項９）。ここでいうＲｍａｘは，ＪＩＳ Ｂ０６０１−１９８２に示されている最大高さであって，その測定方法も上記ＪＩＳ規格に規定された方法を用いる。
【００２８】
上記第１金属部材の表面粗さがＲｍａｘで５μｍ未満の場合には，上記接合方法による接合力が十分に得られない場合があり，それ故，より好ましくは１０μｍ以上がよい。一方，上記Ｒｍａｘが１００μｍを超える場合には，接合界面に空気層（隙間）が残り接合強度が低下するという問題があり，それ故，より好ましくは５０μｍ以下がよい。
【００２９】
次に，上記第２の発明（請求項１０）の好ましい実施の形態について説明する。
上記第２の発明においては，上記のごとく，回転工具の突起部を第２金属部材から差し込み，これを第１金属部材の表面に接触させてその面粗しを実施する。この際，上記突起部と第１金属部材との接触が強すぎると，面粗しの目的を外れ，第１金属部材あるいは回転工具にダメージを与えるおそれがある。そのため，上記第２の発明においては，上記突起部と上記第１金属部材との接触深さが１００μｍ以下であることが好ましい。
【００３０】
また，第２の発明においても，上記と同様の理由により，上記突起部を上記第２金属部材に差し込んだ際には，上記肩面をも該第２金属部材内部に差し込み，かつ上記肩面の差し込み量は，上記第２金属部材における上記肩面を差し込む部位の厚みの３０％以下とする。
【００３１】
また，上記第２の発明においても，第１の発明と同様に，上記第１金属部材は鋼部材であり，上記第２金属部材はアルミニウム合金部材であることが好ましい（請求項１１）。
【００３２】
また，上記いずれの発明においても，上記回転工具としては，高硬度の工具鋼又は超硬等の材料より構成したものを用いることができる。
【００３３】
【実施例】
本発明の実施例に係る異種金属接合部材及び異種金属部材の接合方法につき，図１〜図７を用いて説明する。
（実施例１）
本例は，図１，図２に示すごとく，融点の異なる異種金属よりなる２種類の金属部材として，第１金属部材１と第２金属部材２を準備し，点接合をした例である。第１金属部材１は厚さＴ1が１ｍｍの冷延鋼板（ＳＰＣＣ）であり，第２金属部材２は厚さＴ2が１ｍｍのアルミニウム合金板（５１８２）である。
本例では，冷延鋼板よりなる第１金属部材１の接合界面となる表面をあらかじめペーパーで研磨し，表面粗さがＲａで５μｍ，Ｒｍａｘで２０μｍになっていることを確認した。
【００３４】
また，回転工具５としては，図１，図２に示すごとく，肩面５１と該肩面５１から突出させた突起部５５とを先端に有すると共に上記第２金属部材２よりも硬質の回転工具を用いた。より具体的には，本例の回転工具５は，図２に示すごとく，突起部５２の長さＬが０．９ｍｍ，外径Ｄ1が３ｍｍ，肩面５１の肩径Ｄ2が１２ｍｍの硬質回転工具である。
【００３５】
上記２つの異種金属材料を接合するに当たっては，図１に示すごとく，まず，第１金属部材１と第２金属部材２とを，融点の低い方のアルミニウム合金板よりなる第２金属部材２を上にして重ね合わせる。
次に，回転工具５を回転数１５００ｒｐｍで回転させながら突起部５２を第２金属部材２の表面から差し込み，肩面５１がその表面に当接するまで前進させる。そして，その後すぐに回転工具５を後退させて引き抜く。
【００３６】
このとき，回転工具５が差し込まれた状態においては，図２に示すごとく，突起部５２は第１金属部材１と直接接触することなく間隔を保っている。本例では，その間隔Ｋは約０．１ｍｍに設定した。上記回転工具５の回転によって，第２金属部材２の金属が摩擦熱を発生させた状態で撹拌され，その撹拌域２５が第１金属部材１に達する範囲に形成される。これにより，第１金属部材１と第２金属部材２とが接合され，冷延鋼板とアルミニウム合金板との異種金属を接合してなる異種金属接合部材が得られる。
【００３７】
次に，本例では，得られた異種金属接合部材の接合強度を引張剪断荷重を測定することにより評価した。
継手の引張剪断荷重の測定は，ＪＩＳ Ｚ ３１３６に規定されている方法により行った。その結果，継手の引張剪断荷重は４．１ｋＮと非常に高かった。
【００３８】
また，接合部の断面観察および分析も行った。断面観察は，観察部位を樹脂に埋め込み，観察断面を研磨して現出させ，その断面を５％フッ酸によりエッチングして組織観察した。また，分析では，断面観察したサンプルを用い，ＥＰＭＡ面分析により金属間化合物の元素の分析を行った。
その結果，接合界面では脆いＦｅ−Ａｌ系の金属間化合物の層は１μｍ以上の厚さには成長しておらず，欠陥のない健全な接合部であった。
【００３９】
なお，本例では，突起部５２を差し込んだ際の回転工具５の肩面５１の位置を，ほぼ第２金属部材２の表面位置と同じ位置に保持した。これに代えて，肩面５１を第２金属部材２にめり込むように差し込むこともでき，この場合には撹拌領域２５を大きくすることができるので，さらに接合強度の向上を図ることができる。
【００４０】
（比較例１）
比較例１は，実施例１と同じ第１金属部材と第２金属部材を用い，これらをスポット溶接した例である。
即ち，まず厚さ１ｍｍの冷延鋼板（ＳＰＣＣ）と厚さ１ｍｍのアルミニウム合金板（５１８２）を重ねて拘束した。接合界面に当たる鋼板の表面は，あらかじめペーパーで研磨し，表面粗さがＲａで５μｍ，Ｒｍａｘで２０μｍになっていることを確認しておいた。
【００４１】
次いで，単相交流抵抗スポット溶接機を用いて２５ｋＡ，２７０ＭＰａで第１金属部材と第２金属部材との溶接を行った。
得られた異種金属接合部材の接合強度を実施例１と同様に引張剪断荷重を測定することにより評価した。その結果，継手の引張剪断荷重は１．５ｋＮと低かった。
また，実施例１と同様に断面観察および分析を行った結果，界面では脆いＦｅ−Ａｌ系等の金属間化合物の層が２〜８μｍ以上の厚さに成長していた。
【００４２】
（実施例２）
本例では，実施例１における第１金属部材１の冷延鋼板に代えて，厚さ１ｍｍの亜鉛めっき鋼板を用いて同様に点接合した。
そして，実施例１と同様に継手の引張剪断荷重を測定した結果，３．６ｋＮと高かった。
【００４３】
（実施例３）
本例では，実施例１における第１金属部材１の冷延鋼板に代えて，厚さ３ｍｍのマグネシウム鋳物用い，第２金属部材２のアルミニウム合金板に代えて厚さ２ｍｍのアルミニウム合金板（６Ｎ０１）を用い，このアルミニウム合金板を上にして重ねて拘束し，実施例１と同様に点接合を行った。
【００４４】
本例では，回転工具として，突起部の長さが１．９ｍｍ，外径が４ｍｍ，肩面の肩径が１５ｍｍの硬質回転工具を用いた。そして，この回転工具を，実施例１と同様に，アルミニウム合金板側から回転数２０００ｒｐｍで回転させながら肩面がアルミニウム合金板の表面に当たるまで差し込み，すぐに抜いて重ね接合した。
【００４５】
本例においても，実施例１と同様に得られた異種金属接合部材の接合強度を引張剪断荷重を測定すると共に，接合部の断面観察および分析を行った。
その結果，継手の引張剪断荷重は７．２ｋＮと高かった。断面観察および分析の結果，界面では脆いＡｌ−Ｍｇ系の金属間化合物の層は１μｍ以上の厚さには成長していなかった。
【００４６】
（実施例４）
本例は，図３に示すごとく，異種金属部材を線接合により接合した例である。即ち，同図に示すごとく，まず第１金属部材１としての厚さ８ｍｍの鋼板の上に，第２金属部材２としての厚さ３ｍｍの１１００アルミニウム合金板を載せて固定した。
【００４７】
回転工具５としては，突起部の長さ２．８ｍｍ，突起部の外径５ｍｍ，肩面の肩径２０ｍｍの硬質回転工具を用いた。そしてこの回転工具５を第２金属部材２のアルミニウム合金板側から回転数３０００ｒｐｍで回転させながら肩面が第２金属部材２の表面に当たるまで差し込んだ。そして回転工具５の突起部を第２金属部材２に差し込んだ状態で，第１金属部材２と第２金属部材２との接合界面に平行に，５００ｍｍ／ｍｉｎの速度で移動させた。これにより，撹拌領域２５の軌跡が線状の接合部として得られた。
【００４８】
得られた異種金属接合部材について，その引張剪断荷重を測定すると共に，接合部の断面観察および分析を行った。本例での引張剪断荷重の測定は，ＪＩＳ Ｚ ３１２１の規定に従った。断面観察及び分析方法は実施例１と同様である。その結果，継手の引張剪断荷重は７．５ｋＮと高かった。断面観察および分析の結果，接合部に欠陥はなく，界面では脆いＡｌ−Ｍｇ系の金属間化合物の層は１μｍ以上の厚さには成長していなかった。
【００４９】
（実施例５）
本例では，図４に示すごとく，第１金属部材１としての０．７ｍｍ×５００ｍｍ×２００ｍｍの鋼板と，第２金属部材２としての１．０ｍｍ×５００ｍｍ×７００ｍｍの６０００系アルミニウム合金板の５００ｍｍ側の端部を重ね代Ｓが１５ｍｍとなるように重ねて拘束して線接合した。
【００５０】
接合界面に当たる鋼板（第１金属部材１）は，重なる部分の表面をあらかじめ凹凸のついた最終仕上げロールで圧延し，その部分の表面粗さがＲａで３μｍ，Ｒｍａｘで１５μｍになっていることを確認した。
回転工具５としては，突起部の長さ０．９ｍｍ，突起部の外径３ｍｍ，肩面の肩径１２ｍｍの硬質回転工具を用いた。そして，回転工具５をアルミニウム合金板（第２金属部材２）側から回転数１５００ｒｐｍで回転させながら肩面が第２金属部材の表面に当たるまで差し込み，重ねた部分に沿って直線的に移動した。これにより，重ねた部分に線接合部が形成された。
【００５１】
得られた異種金属接合部材の断面観察および分析を行った結果，界面では脆いＦｅ−Ａｌ系等の金属間化合物の層は１μｍ以上の厚さには成長しておらず，欠陥のない健全な接合部が得られていたことが分かった。
また，本例で得られた異種金属接合部材は，いわゆる異材差厚テーラードブランクとして用いることができる。そのため，これを自動車のドアインナーの形にプレス成形する試験を行った結果，割れを生じることなしに成形することができた。
【００５２】
（実施例６）
本例は，図５に示すごとく，実施例４と同様に異種金属部材を線接合により接合した例であるが，実施例４の回転工具に代えて，突起部５２が長い回転工具５を用いてその先端５２０を第１金属部材１に接触させた例である。
【００５３】
即ち，同図に示すごとく，まず第１金属部材１としての厚さ８ｍｍの鋼板の上に，第２金属部材２としての厚さ３ｍｍの１１００アルミニウム合金板を載せて固定した。
回転工具５としては，突起部５２の長さ３．０ｍｍ，突起部５２の外径５ｍｍ，肩面５１の肩径２０ｍｍの硬質回転工具を用いた。そしてこの回転工具５を第２金属部材２のアルミニウム合金板側から回転数３０００ｒｐｍで回転させながら肩面が第２金属部材２の表面に当たるまで差し込んだ。また，この状態で，突起部５２の先端は第１金属部材１の表面にわずかに接触している。
【００５４】
そして回転工具５を，第１金属部材２と第２金属部材２との界面に平行に，５００ｍｍ／ｍｉｎの速度で移動させた。これにより，撹拌領域２５の軌跡が線状の接合部として得られた。このとき，本例では，接合界面における第１金属部材１の表面が，順次回転工具５によって面粗しされ，その粗い表面に撹拌領域２５が到達して線状の接合部が形成される。
【００５５】
得られた異種金属接合部材について，その引張剪断荷重を測定すると共に，接合部の断面観察および分析を行った。
その結果，継手の引張剪断荷重は６．８ｋＮと高かった。断面観察および分析の結果，接合部に欠陥はなく，界面では脆いＡｌ−Ｍｇ系の金属間化合物の層は１μｍ以上の厚さには成長していなかった。
【００５６】
（実施例７）
本例は，図６，図７に示すごとく，異種金属部材を線接合により隅肉接合した例である。
まず図６に示すごとく，第１金属部材１としての厚さ８ｍｍの鋼板の上に，第２金属部材２としての厚さ３ｍｍの１１００アルミニウム合金板を載せて固定した。このとき，第２金属部材２の端面２８が第１金属部材１の表面上に位置するように第２金属部材２を配置した。
【００５７】
回転工具５としては，突起部５２の長さ１ｍｍ，突起部５２の外径５ｍｍ，肩面の肩径２０ｍｍの硬質回転工具を用いた。そしてこの回転工具５を第２金属部材２のアルミニウム合金板側から回転数３０００ｒｐｍで回転させながら，第２金属部材２の端面２８の近傍から，斜めに前進させて差し込んだ。具体的には，上記突起部５２の方向，即ち回転工具５の軸線方向Ｃ２を，第１金属部材１と第２金属部材２との接合界面に対する垂直方向Ｃ１から８°傾斜させた状態で差し込んだ。
【００５８】
図７に示すごとく，回転工具５を第２金属部材２に差し込んだ状態では，第１金属部材１と第２金属部材２との接合界面と肩面５１とのなす角度βが上記傾斜角αと同じ８°となり，突起部５２の先端と第１金属部材１との間隔Ｋが約０．１ｍｍとなっている。
本例では，このように突起部５２を差し込んで回転させることによって，断面くさび状の撹拌領域２５が形成される。
【００５９】
そして回転工具５の突起部５２を第２金属部材２に差し込んだ状態で，第１金属部材２と第２金属部材２との接合界面に平行に，５００ｍｍ／ｍｉｎの速度で移動させた。これにより，撹拌領域２５の軌跡が，第２金属部材２の端面２８に沿って線状に得られ，線状の接合部が形成された。
この場合には，いわゆる隅肉部の溶接を行うことができ実施例４とほぼ同様の接合特性が得られた。
【図面の簡単な説明】
【図１】実施例１における，異種金属部材の接合方法を示す説明図。
【図２】実施例１における，回転工具を第２金属部材に差し込んだ状態を示す説明図。
【図３】実施例４における，異種金属部材を線接合により接合している状態を示す説明図。
【図４】実施例５における，異種金属部材を線接合により接合している状態を示す説明図。
【図５】実施例６における，回転工具を第２金属部材に差し込んだ状態を示す説明図。
【図６】実施例７における，回転工具を第２金属部材に差し込む前の状態を示す説明図。
【図７】実施例７における，回転工具を第２金属部材に差し込んだ状態を示す説明図。
【符号の説明】
１．．．第１金属部材，
２．．．第２金属部材，
２５．．．撹拌領域，
５．．．回転工具，
５１．．．突起部，
５２．．．肩面，[0001]
【Technical field】
The present invention relates to a method for joining dissimilar metals using a friction stir welding method and a dissimilar metal joining member.
[0002]
[Prior art]
For example, there are cases where it is desired to use dissimilar metal members such as steel materials and aluminum alloy materials. In this case, when both are joined by conventional fusion welding, a brittle intermetallic compound (Fe 2 Al 5 or the like) is generated at the joint interface, which causes a problem of low joint strength. Such a problem also applies to joining of an aluminum alloy and a magnesium alloy and joining of other dissimilar metal members. For this reason, explosive bonding, adhesion, rotational friction welding, joining with rivets or bolts, and caulking have been adopted as joining methods for dissimilar metal members other than fusion welding.
[0003]
[Problems to be solved]
However, the conventional method for joining dissimilar metal members has the following problems.
That is, the above-mentioned explosion requires a large-scale facility, and further requires an environment where explosion noise is not a problem. In addition, the above-mentioned bonding takes a long time to cure and has low long-term reliability. The above rotational friction welding also has a problem in reliability. Mechanical joining with rivets or bolts requires a third member such as these bolts and may cause loosening. In addition, joining by caulking has low joining strength and may cause loosening.
[0004]
Against this background, there has been a demand for the development of a method capable of joining dissimilar metal members more easily and reliably than before.
The present invention has been made in view of such conventional problems, and intends to provide a joining method capable of easily and reliably joining dissimilar metal members and a dissimilar metal joining member formed by joining the joining methods. It is.
[0005]
[Means for solving problems]
The first invention is a method of joining two types of metal members made of different metals having different melting points,
The first metal member with the higher melting point and the second metal member with the lower melting point are overlapped,
Using a rotary tool having a shoulder surface and a protrusion protruding from the shoulder surface at the tip and harder than the second metal member,
The protrusion is inserted from the surface of the second metal member while rotating the rotary tool, and a gap is maintained between the tip of the protrusion and the first metal member, and the metal of the second metal member is inserted. In the state in which frictional heat is generated, stirring is performed, and the stirring region is formed in a range reaching the first metal member, thereby joining the first metal member and the second metal member,
When the protrusion is inserted into the second metal member, the shoulder surface is also inserted into the second metal member, and the shoulder surface is inserted into the shoulder surface of the second metal member. Ri der than 30% of the sites of thickness,
The dissimilar metal member joining method is characterized in that an interval between the tip of the protrusion and the first metal member is 0.05 mm or more and less than 0.5 mm (Claim 1).
[0006]
In the joining method of the present invention, the first metal member and the second metal member are overlapped and joined using the same rotary tool as the rotary tool used in the so-called friction stir welding method. At this time, as described above, the rotating tool is inserted into the second metal member having a lower melting point, and is positioned with a gap so that it does not directly contact the first metal member.
[0007]
Then, the metal of the second metal member is agitated by the rotary tool in a state in which frictional heat is generated, and the agitation zone is defined between the surface of the first metal member, that is, the first metal member and the second metal member. It reaches even the joint interface. Thereby, the agitated metal of the second metal member is firmly joined to the first metal member.
[0008]
And since the joined portion of the first metal member and the second metal member is formed without melting, a brittle intermetallic compound is generated and the joining strength is lowered as in the case of fusion welding. No problems arise. Furthermore, problems in other conventional joining methods can be solved, and the first metal member and the second metal member, which are different metals, can be joined easily and reliably.
[0009]
Moreover, in this invention, it joins, without making the said rotary tool contact the said 1st metal member directly. Therefore, even if the first metal member has a very high hardness, the joining can be realized without damaging the first metal member or the rotary tool.
[0010]
As described above, according to the present invention, it is possible to provide a joining method capable of easily and reliably joining dissimilar metal members.
[0011]
The second invention is a method of joining two types of metal members made of different metals having different melting points,
The first metal member with the higher melting point and the second metal member with the lower melting point are overlapped,
Using a rotary tool having a shoulder surface and a protrusion protruding from the shoulder surface at the tip and harder than the first metal member,
While rotating the rotary tool, the protrusion is inserted from the surface of the second metal member, and the protrusion is brought into direct contact with the first metal member to increase the surface roughness. The metal is agitated in a state where frictional heat is generated, the agitation zone is formed in a range reaching the first metal member, and the rotary tool is joined to the interface between the first metal member and the second metal member. When the first metal member and the second metal member are line-joined by moving in parallel to
When the protrusion is inserted into the second metal member, the shoulder surface is also inserted into the second metal member, and the shoulder surface is inserted into the shoulder surface of the second metal member. Ri der than 30% of the sites of thickness,
The contact depth between the protrusion and the first metal member is 100 μm or less .
[0012]
In the joining method of the present invention, as described above, the rotating tool is harder than the first metal member. Then, while rotating the rotary tool, the rotary tool is inserted into the second metal member having a lower melting point, and the protrusion is brought into direct contact with the first metal member. Thereby, the surface of the first metal member can be roughened by the protrusion.
[0013]
Then, the metal of the second metal member is stirred in a state in which frictional heat is generated by moving the rotary tool in parallel to the joining interface while rotating the rotary tool, and the stirring area is roughened on the surface of the first metal member. To reach the surface. As a result, the agitated metal of the second metal member is firmly joined to the first metal member, and a linear joint along the movement of the rotary tool is formed.
[0014]
In particular, in the present invention, the surface of the first metal member can be roughened by the rotary tool, and this surface can be used as a bonding interface, so that a stronger bonding effect can be obtained. Moreover, it is not necessary to roughen the surface of the first metal member in advance. In other respects, the same effects as those of the first invention can be obtained.
As described above, also according to the second aspect of the invention, it is possible to provide a joining method capable of easily and reliably joining dissimilar metal members.
[0015]
A dissimilar metal joining member obtained by joining two kinds of metal members made of dissimilar metals having different melting points, wherein the dissimilar metals are joined by the joining method of the first invention or the second invention. There is a joining member .
This dissimilar metal joining member is joined by the superior joining method of the first invention or the second invention. Therefore, compared to dissimilar metal joining members joined by fusion welding or other joining methods, the joining reliability is high and no loosening occurs. Therefore, the application range of the dissimilar metal joining member of the present invention can be expanded as compared with the conventional case.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
First, a preferred embodiment of the first invention (claim 1) will be described.
The distance between the tip of the protrusion and the first metal member when the protrusion is inserted into the second metal member is 50% or less of the thickness of the portion into which the protrusion is inserted in the second metal member. (Claim 2).
[0017]
When the interval exceeds 50%, the stirring area formed by the rotation of the rotary tool does not reach the first metal member, or even if it reaches, the contact area becomes small, and there is a possibility that sufficient joining cannot be obtained. Therefore, more preferably, the interval is set to 30% or less of the thickness of the portion into which the protruding portion of the second metal member is inserted.
In particular, the absolute value of the interval is preferably less than 0.5 mm. If the thickness exceeds 0.5 mm, the area where the stirring region as described above contacts the first metal member becomes small, and the problem that the bonding strength becomes weak tends to occur. In addition, in order to implement | achieve the stable joining operation | work, it is preferable to set the said space | interval to 0.05 mm or more.
[0018]
It is preferable that the protruding portion of the rotary tool has a protruding amount smaller than a thickness of a portion of the second metal member into which the protruding portion is inserted. In this case, when the rotary tool is inserted into the second metal member, it is possible to more reliably avoid the protrusion from coming into contact with the first metal member.
[0019]
Further, when the protrusion is inserted into the second metal member, the shoulder surface is also inserted into the second metal member, and the amount of insertion of the shoulder surface is the shoulder surface of the second metal member. 30% or less of the thickness of the part into which is inserted . In this case, the stirring region can be widened by rotation with the shoulder surface inserted, and the strength of the joint can be increased. On the other hand, when the insertion amount of the shoulder surface exceeds 30% of the thickness of the insertion portion, there is a problem that the thickness of the joint portion becomes thin and the effect of improving the joint strength is lowered. Therefore, more preferably, the insertion amount of the shoulder surface is 10% or less of the thickness of the insertion portion.
[0020]
After inserting the protruding portion into the second metal member, it is preferable to carry out the spot bonding by pulling in the direction of insertion opposite to the direction (claim 4). In this case, joining can be easily realized by inserting the second metal member into the second metal member while rotating the rotary tool, and pulling it back as it is. Therefore, the structure of the joining device, joining work, etc. can be simplified.
[0021]
In addition, it is possible to perform line bonding by moving the rotary tool in parallel to the bonding interface between the first metal member and the second metal member in a state where the protrusion is inserted into the second metal member. (Claim 5 ). In this case, a linear joining portion can be formed, and a stronger joining can be realized.
[0022]
In addition, the second metal member is arranged so that the end surface of the second metal member is located on the surface of the first metal member, and the protrusion of the rotary tool is connected to the end surface of the second metal member or the end thereof. It is also possible to insert from the vicinity in a state where the first metal member and the second metal member are inclined at a predetermined angle from the direction perpendicular to the bonding interface (Claim 6 ). In this case, so-called fillet joining can be realized.
[0023]
Further, the first metal member is a steel member, it is preferable that the second metal member is an aluminum alloy member (claim 7). In this case, the effect of the joining method can be expressed particularly effectively, and the steel member and the aluminum alloy member, which have been difficult in the past, can be easily and firmly joined.
[0024]
Further, it is preferable that at least that surface roughness of the first metal member at the bonding interface between the second metal member is in the range of 1~20μm in Rz (claim 8). Here, Rz is a ten-point average roughness shown in JIS B0601-1982, and the method defined in the JIS standard is used as the measuring method.
[0025]
In addition, there are various methods for adjusting the surface roughness, such as polishing with a polishing tool such as paper or file, etching, surface roughening by irradiation with a high-density energy beam such as a laser, rolling using an uneven roll, and the like. Can be used. The surface roughness may be adjusted at least on the surface that becomes the bonding interface.
[0026]
When the surface roughness of the first metal member is less than 1 μm in terms of Rz, the bonding force by the bonding method may not be sufficiently obtained, and therefore, more preferably 2 μm or more. On the other hand, when the Rz exceeds 20 μm, there is a problem that an air layer (gap) remains at the bonding interface and the bonding strength is lowered. Therefore, the thickness is preferably 10 μm or less.
[0027]
Further, it is preferable that at least that surface roughness of the first metal member at the bonding interface between the second metal member is in the range of 5~100μm in Rmax (claim 9). Here, Rmax is the maximum height shown in JIS B0601-1982, and the measurement method uses the method defined in the JIS standard.
[0028]
When the surface roughness of the first metal member is less than 5 μm in Rmax, the bonding force by the bonding method may not be sufficiently obtained, and therefore, more preferably 10 μm or more. On the other hand, when the above Rmax exceeds 100 μm, there is a problem that an air layer (gap) remains at the bonding interface and the bonding strength is lowered. Therefore, the thickness is preferably 50 μm or less.
[0029]
Next, a preferred embodiment of the second invention (claim 10 ) will be described.
In the second invention, as described above, the protrusion of the rotary tool is inserted from the second metal member and brought into contact with the surface of the first metal member to roughen the surface. At this time, if the contact between the protrusion and the first metal member is too strong, the purpose of surface roughening may be lost, and the first metal member or the rotary tool may be damaged. Therefore, in the second invention, it is preferable that a contact depth between the protrusion and the first metal member is 100 μm or less.
[0030]
In the second invention, for the same reason as described above, when the protrusion is inserted into the second metal member, the shoulder surface is also inserted into the second metal member, and the shoulder surface is also inserted. amount insertion of is 30% or less of the thickness of the portion inserted the shoulder surface in the second metal member.
[0031]
Further, the in the second invention, similar to the first invention, the first metal member is a steel member, it is preferable that the second metal member is an aluminum alloy member (claim 11).
[0032]
In any of the above inventions, the rotary tool may be made of a material such as high hardness tool steel or carbide.
[0033]
【Example】
A dissimilar metal joining member and a dissimilar metal member joining method according to an embodiment of the present invention will be described with reference to FIGS.
Example 1
In this example, as shown in FIGS. 1 and 2, the
In this example, the surface which becomes the joint interface of the
[0034]
As shown in FIGS. 1 and 2, the
[0035]
In joining the two dissimilar metal materials, as shown in FIG. 1, first, the
Next, while rotating the
[0036]
At this time, in the state in which the
[0037]
Next, in this example, the joining strength of the obtained dissimilar metal joining member was evaluated by measuring the tensile shear load.
The tensile shear load of the joint was measured by the method specified in JIS Z 3136. As a result, the tensile shear load of the joint was very high at 4.1 kN.
[0038]
We also performed cross-sectional observation and analysis of the joint. In the cross-sectional observation, the observation site was embedded in a resin, the observation cross section was polished and revealed, and the cross section was etched with 5% hydrofluoric acid to observe the structure. In the analysis, an element of an intermetallic compound was analyzed by EPMA surface analysis using a sample observed in a cross section.
As a result, the brittle Fe—Al intermetallic compound layer did not grow to a thickness of 1 μm or more at the joint interface, and was a healthy joint with no defects.
[0039]
In this example, the position of the
[0040]
(Comparative Example 1)
Comparative Example 1 is an example in which the same first metal member and second metal member as in Example 1 were used, and these were spot welded.
That is, first, a cold rolled steel plate (SPCC) having a thickness of 1 mm and an aluminum alloy plate (5182) having a thickness of 1 mm were stacked and restrained. The surface of the steel sheet which hits the bonding interface was previously polished with paper, and it was confirmed that the surface roughness was 5 μm for Ra and 20 μm for Rmax.
[0041]
Next, the first metal member and the second metal member were welded at 25 kA and 270 MPa using a single-phase AC resistance spot welder.
The joint strength of the obtained dissimilar metal joint member was evaluated by measuring the tensile shear load in the same manner as in Example 1. As a result, the tensile shear load of the joint was as low as 1.5 kN.
Further, as a result of cross-sectional observation and analysis in the same manner as in Example 1, a brittle intermetallic compound layer such as an Fe—Al-based layer grew to a thickness of 2 to 8 μm or more at the interface.
[0042]
(Example 2)
In this example, instead of the cold-rolled steel plate of the
And as a result of measuring the tensile shear load of the joint as in Example 1, it was as high as 3.6 kN.
[0043]
Example 3
In this example, instead of the cold-rolled steel plate of the
[0044]
In this example, a hard rotary tool having a projection length of 1.9 mm, an outer diameter of 4 mm, and a shoulder diameter of 15 mm was used as the rotary tool. Then, in the same manner as in Example 1, this rotating tool was inserted from the aluminum alloy plate side while rotating at a rotational speed of 2000 rpm until the shoulder surface contacted the surface of the aluminum alloy plate, and was immediately removed and overlapped.
[0045]
Also in this example, the tensile strength of the joint strength of the dissimilar metal joint member obtained in the same manner as in Example 1 was measured, and the cross section of the joint was observed and analyzed.
As a result, the tensile shear load of the joint was as high as 7.2 kN. As a result of cross-sectional observation and analysis, the brittle Al—Mg intermetallic compound layer did not grow to a thickness of 1 μm or more at the interface.
[0046]
(Example 4)
In this example, as shown in FIG. 3, dissimilar metal members are joined by wire joining. That is, as shown in the figure, first, a 1100 aluminum alloy plate having a thickness of 3 mm as the
[0047]
As the
[0048]
About the obtained dissimilar metal joint member, the tensile shear load was measured, and the cross-section observation and analysis of the joint part were performed. The tensile shear load in this example was measured according to JIS Z 3121. The cross-sectional observation and analysis method is the same as in Example 1. As a result, the tensile shear load of the joint was as high as 7.5 kN. As a result of cross-sectional observation and analysis, there was no defect at the joint, and a brittle Al—Mg-based intermetallic compound layer did not grow to a thickness of 1 μm or more at the interface.
[0049]
(Example 5)
In this example, as shown in FIG. 4, a steel plate of 0.7 mm × 500 mm × 200 mm as the
[0050]
The steel plate (first metal member 1) that hits the joint interface is rolled with a final finish roll with irregularities in advance, and the surface roughness of that part is 3 μm Ra and 15 μm Rmax. confirmed.
As the
[0051]
As a result of cross-sectional observation and analysis of the obtained dissimilar metal joining member, the layer of the intermetallic compound such as Fe-Al based which is brittle at the interface does not grow to a thickness of 1 μm or more, and there is no defect. It was found that a joint was obtained.
Moreover, the dissimilar metal joining member obtained in this example can be used as a so-called dissimilar material difference thickness tailored blank. Therefore, as a result of performing a test of press molding this into the shape of an automobile door inner, it was possible to mold without causing cracks.
[0052]
(Example 6)
As shown in FIG. 5, this example is an example in which dissimilar metal members are joined by wire joining in the same manner as in Example 4. However, instead of the rotating tool of Example 4, a
[0053]
That is, as shown in the figure, first, a 1100 aluminum alloy plate having a thickness of 3 mm as the
As the
[0054]
Then, the
[0055]
About the obtained dissimilar metal joint member, the tensile shear load was measured, and the cross-section observation and analysis of the joint part were performed.
As a result, the tensile shear load of the joint was as high as 6.8 kN. As a result of cross-sectional observation and analysis, there was no defect at the joint, and a brittle Al—Mg-based intermetallic compound layer did not grow to a thickness of 1 μm or more at the interface.
[0056]
(Example 7)
In this example, as shown in FIGS. 6 and 7, different metal members are fillet joined by wire joining.
First, as shown in FIG. 6, an 1100 aluminum alloy plate having a thickness of 3 mm as the
[0057]
As the
[0058]
As shown in FIG. 7, in the state where the
In this example, the stirring
[0059]
The
In this case, the so-called fillet portion could be welded, and substantially the same joining characteristics as in Example 4 were obtained.
[Brief description of the drawings]
FIG. 1 is an explanatory view showing a method for joining dissimilar metal members in Example 1. FIG.
FIG. 2 is an explanatory view showing a state where a rotary tool is inserted into a second metal member in the first embodiment.
FIG. 3 is an explanatory view showing a state where dissimilar metal members are joined by wire joining in Example 4.
4 is an explanatory view showing a state where dissimilar metal members are joined by wire joining in Example 5. FIG.
FIG. 5 is an explanatory view showing a state where a rotary tool is inserted into a second metal member in Embodiment 6.
6 is an explanatory view showing a state before the rotary tool is inserted into the second metal member in Embodiment 7. FIG.
7 is an explanatory view showing a state where a rotary tool is inserted into a second metal member in Embodiment 7. FIG.
[Explanation of symbols]
1. . . First metal member,
2. . . Second metal member,
25. . . Stirring zone,
5. . . Rotating tool,
51. . . protrusion,
52. . . Shoulder,
Claims (11)
融点の高い方の第１金属部材と，融点の低い方の第２金属部材とを重ね合せ，
肩面と該肩面から突出させた突起部とを先端に有すると共に上記第２金属部材よりも硬質の回転工具を用い，
該回転工具を回転させながら上記突起部を上記第２金属部材の表面から差し込み，上記突起部の先端と上記第１金属部材との間に間隔を保持すると共に，上記第２金属部材の金属を摩擦熱を発生させた状態で撹拌し，その撹拌域を上記第１金属部材に達する範囲に形成することにより，上記第１金属部材と上記第２金属部材とを接合するに当たり，
上記突起部を上記第２金属部材に差し込んだ際には，上記肩面をも該第２金属部材内部に差し込み，かつ上記肩面の差し込み量は，上記第２金属部材における上記肩面を差し込む部位の厚みの３０％以下であり，
上記突起部の先端と上記第１金属部材との間の間隔は０．０５ｍｍ以上０．５ｍｍ未満であることを特徴とする異種金属部材の接合方法。A method of joining two kinds of metal members made of different metals having different melting points,
The first metal member with the higher melting point and the second metal member with the lower melting point are overlapped,
Using a rotary tool having a shoulder surface and a protrusion protruding from the shoulder surface at the tip and harder than the second metal member,
The protrusion is inserted from the surface of the second metal member while rotating the rotary tool, and a gap is maintained between the tip of the protrusion and the first metal member, and the metal of the second metal member is inserted. In the state in which frictional heat is generated, stirring is performed, and the stirring region is formed in a range reaching the first metal member, thereby joining the first metal member and the second metal member,
When the protrusion is inserted into the second metal member, the shoulder surface is also inserted into the second metal member, and the shoulder surface is inserted into the shoulder surface of the second metal member. 30% or less of the thickness of the part,
The dissimilar metal member joining method, wherein a distance between the tip of the protrusion and the first metal member is 0.05 mm or more and less than 0.5 mm.
融点の高い方の第１金属部材と，融点の低い方の第２金属部材とを重ね合せ，
肩面と該肩面から突出させた突起部とを先端に有すると共に上記第１金属部材よりも硬質の回転工具を用い，
該回転工具を回転させながら上記突起部を上記第２金属部材の表面から差し込み，上記突起部を上記第１金属部材に直接接触させてその表面粗さを粗くすると共に，上記第２金属部材の金属を摩擦熱を発生させた状態で撹拌し，その撹拌域を上記第１金属部材に達する範囲に形成し，かつ，上記回転工具を上記第１金属部材と上記第２金属部材との接合界面に平行に移動させることにより，上記第１金属部材と上記第２金属部材とを線接合するに当たり，
上記突起部を上記第２金属部材に差し込んだ際には，上記肩面をも該第２金属部材内部に差し込み，かつ上記肩面の差し込み量は，上記第２金属部材における上記肩面を差し込む部位の厚みの３０％以下であり，
上記突起部と上記第１金属部材との接触深さが１００μｍ以下であることを特徴とする異種金属部材の接合方法。A method of joining two kinds of metal members made of different metals having different melting points,
The first metal member with the higher melting point and the second metal member with the lower melting point are overlapped,
Using a rotary tool having a shoulder surface and a protrusion protruding from the shoulder surface at the tip and harder than the first metal member,
While rotating the rotary tool, the protrusion is inserted from the surface of the second metal member, and the protrusion is brought into direct contact with the first metal member to increase the surface roughness. The metal is agitated in a state where frictional heat is generated, the agitation zone is formed in a range reaching the first metal member, and the rotary tool is joined to the interface between the first metal member and the second metal member. When the first metal member and the second metal member are line-joined by moving in parallel to
When the protrusion is inserted into the second metal member, the shoulder surface is also inserted into the second metal member, and the shoulder surface is inserted into the shoulder surface of the second metal member. Ri der than 30% of the sites of thickness,
The method for joining dissimilar metal members, wherein a contact depth between the protrusion and the first metal member is 100 μm or less .
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| JP2008006451A (en) * | 2006-06-27 | 2008-01-17 | Sumitomo Light Metal Ind Ltd | Friction stir spot-welded body |
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| JP2008006451A (en) * | 2006-06-27 | 2008-01-17 | Sumitomo Light Metal Ind Ltd | Friction stir spot-welded body |
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